Processing, May 2018

Does Valve Selection Matter in High Solid Content Mediums or Abrasive Slurries MAY 2018 www processingmagazine com 19 Figure 2 Predictive maintenance to find optimum in Overall Equipment Effectiveness OEE prediction automatic alerts can be sent to the appropriate stakeholders such as control room personnel or field engineers to take appropriate action in the event of process deviation The notifications can even include recommendations for mitigating actions Another example is by using hypothesis generation for diagnosing issues that fuel new event based predictions Behavior in one part of the production line can then be correlated with future behavior downstream Automatic regression of process parameters is for example used to make soft sensors to predict product quality Asset performance predictive maintenance Asset performance or Overall Equipment Effectiveness OEE depends greatly on the process in which the asset operates Instead of using equipment related sensor data for performance analysis all process related sensor data should be taken into account This is called contextualization of asset performance with process data and with this databased predictive maintenance becomes possible The goal of predictive maintenance is to be able to perform maintenance at a time when it is not only the most cost effective but also when it will have the least impact on operations By representing all sensor generated data in a graph especially when multiple tags need investigation it is hard to find correlations Self service analytics tools allow the user to quickly explore and filter data visually and search through large amounts of process data easily up to multiple years of historical data The advanced analytics capabilities can also help determine root cause analysis RCA test hypothesis discovery analytics and quickly find similar behavioral occurrences Through diagnostic analysis the process engineer can understand the effects of process changes comparing before to after and find potential influence factors for specific issues With this information monitors can be created to safeguard best operating zones and maintenance can be predicted Practical use cases with self service predictive analytics One example where asset performance directly relates to process behavior is the fouling of heat exchangers In a reactor with subsequent heating and cooling phases the controlled cooling phase is the most time consuming and it is almost impossible to monitor fouling when the reactor is used for different product grades and different recipes are required for each grade Fouling of heat exchangers increases the cooling time but scheduling maintenance too early leads to unwarranted downtime and scheduling too late leads to degraded performance increased energy consumption and potential risks In the instance of the production of a polymer a monitor was set up to look at the cooling times of the most highly produced products If the duration of the cooling phase starts to increase a warning is sent to the engineers who can then schedule timely maintenance The gained benefits are extended asset availability operational and maintenance cost reduction and reduced safety risk The overall impact in this instance was a more than 1 percent overall revenue increase of the entire production line Within a water distribution network only 5 percent of all pumping stations were responsible for more than 50 percent of the total maintenance costs With self service analytics using scatter plots and statistical fingerprints the pumps could be monitored within their best operating zones Alarms were added and users are now notified when equipment is expected to fail allowing them enough time to take action This has improved performance reliability and lowered overall operational costs The worlds toughest pumps for the most demanding applications Our Dual Pinch and High Quality Rubber Saves Money and Increases Sleeve Lifetime Standard Pinch Valves Sleeve Life 4 Months 1 Year Opex 130 Valves 171950 5 Year Opex 130 Valves 859792 VS F lowrox Pinch Valves Sleeve Life 27 Months 1 Year Opex 130 Valves 0 5 Year Opex 130 Valves 114639 40 pumice slurry @ 60 psi valves cycling every 45 seconds Unmatched Reliability ASK ABOUT A FREE TRIAL 888 356 9797 Your productivity and profitability is our 1 concern www flowrox com Early Detection Stop an entire operation if one machine fails ZERO SPEED SWITCHES Reduce downtime Avoid pileup of material Protect expensive equipment Safeguard operations Switches can be interlocked as part of your conveyor system or other shaft driven process components to ensure if one machine deviates or fails the switch will Actuate a signal or alarm device Break a circuit to a motor Make a circuit to start auxiliary equipment Make or break a circuit to other electrical devices Signal a control station or PLC Contact us to integrate Zero Speed Switches into your system Sales@ ControlConceptsUSA com MADE IN THE USA Electromechanical No electricity required Explosion Proof For indoor hazardous locations Electronic Adjustable time delay Proximity Switch For remote sensing SpeedSwitch com 860 928 6551 Processing 201805 indd 1 4 1 2018 8 29 03 PM Through diagnostic analysis the process engineer can understand the effects of process changes comparing before to after and find potential influence factors for specific issues

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